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Worcester-Bosch GB162-80 Manual

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Contents
6720813171 (2016/05)4
Contents
1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 5
1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Regulations and directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Boiler room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Combustion air flue gas connection . . . . . . . . . . . . . . . . . 9
3.4 Quality of the heating system water . . . . . . . . . . . . . . . . . 9
3.5 Quality of the pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.7 Applicability of regulations . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Please observe these instructions . . . . . . . . . . . . . . . . 10
4.2 Tools, materials and further equipment . . . . . . . . . . . . 10
4.3 Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 Lifting and carrying the boiler . . . . . . . . . . . . . . . . . . . . 10
5.2 Transporting the boiler with a trolley . . . . . . . . . . . . . . 11
6 Items supplied with boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7 Dimensions of boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.1 Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.2 General connection of mains water and gas
components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.2.2 Install the water and gas connections to the boiler
using a pump group (accessory) . . . . . . . . . . . . . . . . . . 15
8.2.3 Install the water and gas connections to the boiler
without a pump group . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.2.4 Installing the differential pressure controller . . . . . . . 16
8.2.5 Installing the isolating valves . . . . . . . . . . . . . . . . . . . . 16
8.2.6 Installing the drain cock . . . . . . . . . . . . . . . . . . . . . . . . 16
8.2.7 Installing a pressure relief valve . . . . . . . . . . . . . . . . . . 16
8.2.8 Selecting and installing the pump . . . . . . . . . . . . . . . . 16
8.2.9 Installing the condensate trap . . . . . . . . . . . . . . . . . . . 17
8.2.10 Condensate removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.2.11 Connecting the condensate drain pipe . . . . . . . . . . . . 19
8.2.12 Connecting the expansion vessel in a single-boiler
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.3 Flue Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.3.1 Siting the flue terminal . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.3.2 Air supply and flue gas exhaust in a room sealed
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.3.3 Maximum Flue length (L) . . . . . . . . . . . . . . . . . . . . . . . 22
8.3.4 Additional flue parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.3.5 Standard 100 mm flue systems . . . . . . . . . . . . . . . . . . . 22
8.3.6 Installation of the horizontal flue . . . . . . . . . . . . . . . . . . 23
8.3.7 Flue pipe preparation and assembly . . . . . . . . . . . . . . . 23
8.4 Flue gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.4.1 Open flue operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.4.2 Room sealed operation . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.4.3 Flue material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.4.4 Calculating the air intake and flue gas pipe
dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.5.1 Electrical wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . 25
8.5.2 Terminal strip connections . . . . . . . . . . . . . . . . . . . . . . . 26
8.5.3 Routing the cable through the boiler . . . . . . . . . . . . . . . 26
8.5.4 Description of the terminal strip connections . . . . . . . . 26
8.5.5 230 V connections (only for GB162-50/65) . . . . . . . . 29
8.5.6 Installing function modules (accessories) . . . . . . . . . . . 30
9 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.1 General items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.2 BC10 control operating instructions . . . . . . . . . . . . . . . 33
10 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10.1 Filling the heating system . . . . . . . . . . . . . . . . . . . . . . . . 37
10.1.1 Filling the heating system . . . . . . . . . . . . . . . . . . . . . . . . 37
10.1.2 Filling the condensate trap with water . . . . . . . . . . . . . 38
10.2 Testing and measuring . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.2.1 Checking for gas leaks . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.2.2 Bleeding the gas flow pipe . . . . . . . . . . . . . . . . . . . . . . . 39
10.2.3 Gas consumption test . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.2.4 Checking the flue gas connection . . . . . . . . . . . . . . . . . 40
10.2.5 Checking the appliance configuration . . . . . . . . . . . . . . 40
10.2.6 Measuring the gas inlet pressure (working pressure) . . 40
10.2.7 Checking and adjusting the gas/air-ratio . . . . . . . . . . . . 41
10.2.8 Carrying out a leakage test in operating conditions . . . 42
10.2.9 Measuring the flue gases CO
2
emissions . . . . . . . . . . . . 43
10.2.10Carrying out a function test . . . . . . . . . . . . . . . . . . . . . . 43
10.2.11Measuring the ionisation current . . . . . . . . . . . . . . . . . . 43
10.3 Boiler settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10.3.1 Setting the heating capacity . . . . . . . . . . . . . . . . . . . . . . 44
10.3.2 Setting the maximum CH flow temperature . . . . . . . . . 44
10.3.3 Setting the pump run-over time . . . . . . . . . . . . . . . . . . . 44
10.3.4 Switching DHW mode on/off . . . . . . . . . . . . . . . . . . . . . 44
10.3.5 Setting the DHW temperature . . . . . . . . . . . . . . . . . . . . 44
10.4 Final activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10.4.1 Closing the boiler door and the control panel . . . . . . . . 45
10.4.2 Handing over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10.5 Commissioning record log book . . . . . . . . . . . . . . . . . . 45
11 Shutting down the heating system . . . . . . . . . . . . . . . . . . . . . . 46
11.1 Shutting down the heating system using the
basic controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11.2 Shutting down the heating system if there is a risk
of freezing (interruption of use) . . . . . . . . . . . . . . . . . . 46
12 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
12.1 Preparing the heating system for inspection . . . . . . . . 46
12.2 Opening the boiler door . . . . . . . . . . . . . . . . . . . . . . . . . 47
… 4 …


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